CEBMOOOI 02

Shop
Manual

Pc2002001c4
PC21OLC=li
PC22OlLli
PC25Olbi
HYDRAULIC EXCAVATOR
PC200-6 - A82001
PC2OOLC-6 - A82001
PC21OLC-6 n A82001
SERIAL NUMBERS PC22OLC-6 n A82001 andup
PC25OLC-6 - A82001
This material is proprietary to Komatsu America lnternational Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.

00-l
October 1996 Copyright 1996 Komatsu America International Company 0
 CONTENTS

01 GENERAL ............................................. 01-I

IO STRUCTURE AND FUNCTION ............................ IO-I

20 TESTING AND ADJUSTMENT ............................. 20-I

30 DISASSEMBLY AND ASSEMBLY .......................... 30-I

40 MAINTENANCE STANDARD .............................. 40-I

00-2
SAFETY SAFETY NOTICE

SAFETY

SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation.
Some of these operations require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols A and *$ are used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS clean and make sure that there is no dirt or oil on the
floor. Smoke only in the areas provided for smoking.
Mistakes in operation are extremely dangerous. Read the Never smoke while working.
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine. PREPARATIONS FOR WORK

1. 3efore carrying out any greasing or repairs, read all 7. Before adding oil or making repairs, park the ma-
:he precautions given on the decals which are fixed to chine on hard, level ground, and block the wheels or
:he machine. tracks to prevent the machine from moving.

2. When carrying out any operation, always wear safety 8. Before starting work, lower blade, ripper, bucket or
shoes and helmet. Do not wear loose work clothes, any otherwork equipment to the ground. If this is not
)r clothes with buttons missing. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure
l Always wear safety glasses when hitting parts with
to lock all the control levers and hang warning signs
a hammer.
on them.
l Always wear safety glasses when grinding parts
with a grinder, etc. 9. When disassembling or assembling, support the
machine with blocks, jacks or stands before starting
3. f welding repairs are needed, always have a trained, work.
experienced welder carry out the work. When carry-
ng out welding work, always wear welding gloves, 10, Remove all mud and oil from the steps or other
apron, glasses, cap and other clothes suited for places used to get on and off the machine. Always
Melding work. use the handrails, ladders or steps when getting on or
off the machine. Never jump on or off the machine.
4. JVhen carrying out any operation with two or more If it is impossible to use the handrails, ladders or
Norkers, always agree on the operating procedure steps, use a stand to provide safe footing.
oefore starting. Always inform your fellow workers
sefore starting any step of the operation. Before PRECAUTIONS DURING WORK
starting work, hang UNDER REPAIR signs on the
zontrols in the operator’s compartment. 11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
5. I<eep all tools in good condition and learn the correct slowly to prevent the oil from spurting out. Before
Nay to use them. disconnecting or removing components of the oil,
water or air circuits, first remove the pressure com-
6. IDecide a place in the repair workshop to keep tools pletely from the circuit.
and removed parts. Always keep the tools and parts
i n their correct places. Always keep the work area 12. The water and oil in the circuits are hot when the

00-3
SAFETY SAFETY NOTICE

engine is stopped, so be careful not to get burned. washing electrical parts.

Wait for the oil and water to cool before carrying out
any work on the oil or water circuits. 19. Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
13. Before starting work, remove the leads from the
l When installing hoses and wires, be sure that
battery. ALWAYS remove the lead from the negative
they will not be damaged by contact with other
(-) terminal first.
parts when the machine is being operated.

14. When raising heavy components, use a hoist or

20. When installing high pressure hoses, make sure that
crane. Check that the wire rope, chains and hooks
they are nottwisted. Damaged tubes are dangerous,
are free from damage. Always use lifting equipment
so be extremely careful when installing tubes for high
which has ample capacity. Install the lifting equip
pressure circuits. Also check that connecting parts
ment at the correct places. Use a hoist or crane and
are correctly installed.
operate slowly to prevent the component from hitting
any other part. Do not work with any part still raised
21. When assembling or installing parts, always use the
by the hoist or crane.
specified tightening torques. When installing protec-
tive parts such as guards, or parts which vibrate
15. When removing covers which are under internal
violently or rotate at high speed, be particularly
pressure or under pressure from a spring, always
careful to check that they are installed correctly.
leave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts to
22. When aligning two holes, never insert your fingers or
remove.
hand. Be careful not to get your fingers caught in a
hole.
16. When removing components, be careful not to break
or damage the wiring, Damaged wiring may cause
23. When measuring hydraulic pressure, check that the
electrical fires.
measuring tool is correctly assembled before taking
any measurements.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, wipe
24. Take care when removing or installing the tracks of
it up immediately. Fuel or oil on the floor can cause
track-type machines. When removing the track, the
you to slip, or can even start fires.
track separates suddenly, so never let anyone stand
at either end of the track.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when

00-4
FOREWARD GENERAL

FOREWARD

GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the following sections. These sections are further divided into each
main group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel,
coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of
the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made
at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also
included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.

00-5
 01 GENERAL

General assembly drawing (PC200-6, PC2OOLC-6, PC21OLC-6) ....... .. .. . . . . . . . .. . . . .Ol- 2

General assembly drawing (PC22OLC-6, PC25OLC-6) ....... ....... .. .. . . . . . . . .. . . . .Ol- 4
Specifications (PC200-6, PC2OOLC-6) ..................... ....... .. .. . . . . . . . .. . . . .Ol- 7
Specifications (PC21 OLC-6) ............................. ....... .. .. . . . . . . . .. . . .Ol- 9
Specifications (PC220LC-6) ............................. ....... .. .. . . . . . . . .. . . . Ol- 11
Specifications (PC25OLC-6) ............................. ....... .. .. . . . . . . .. . . . . Ol- 13
Weight table (PC200-6, PC200LC-6) ...................... ....... .. .. . . . . . . . .. . . . . Ol- 15
Weight table (PC21 OLC-6) .............................. ....... .. .. . . . . . . . .. . . . . Ol- 17
Weight table (PC22OLC-6, PC25OLC-6) ................... ....... .. .. . . . . . . . .. . . . . Ol- 19
Fuel, coolants and lubricants ............................ . . . . . .. . . . . Ol- 21

01-l
PC200-6, PC200LC-6, PC21 OLC-6

XOlAD024

Unit: mm
GENERAL GENERAL ASSEMBLY DRAWING

XOlAD025

Unit: mm
I I I
PC200-6, PC2OOLC-6 Arms
PC21 OLC-6
1.84m 2.4 m * 2.93 m ** 4.06 m

A Maximum digging height 8,895 9,050 9,305 9,700

B Maximum dumping height 6,065 6,255 6,475 6,970

C Maximum digging depth 5,535 6,095 6,602 7,725

I I D Maximum vertical wall

digging depth I
4,965
I
5,315 5,980
I 7,075
I

E Maximum digging depth of 5,160 5,840 6,435 7,590

cut for 8 ’level

F Maximum digging reach 8,915 9,395 9,875 10,880

G Maximum digging reach at 8,720 9,205 9,700 10,705

ground

H Minimum swing radius 3,640 3,710 3,630 3,630

Bucket digging force *** + 14,900 kg 12,700 kg 12,700 kg 12,700 kg

Arm crowd force *** 13,200 kg 11,700 kg 10,000 kg 8,200 kg

* - PC21 OLC-6 available with only this arm *** - At power max
** - 1 .I 3 m Extension + 2.93 m arm ’ - Optional bucket cylinder is required

01-3
GENERAL GENERAL ASSEMBLY DRAWING

PC22OLC-6, PC25OLC-6

/
F

XOlAD024

Q Machine cab height 2,020 2,140

R Engine compartment height 2,255 2,375

S Operator’s cab height 2,905 3,020

01-4
GENERAL GENERAL ASSEMBLY DRAWING

t t
C E

11
- XOlAD025

Unit: mm
PC22OLC-6 Arms

2.0 m 2.5 m 3.05 m 3.5 m

A Maximum digging height 9,070 9,150 9,380 9,620

I I I I I
B 1 Maximum dumping height 1 6,120 I 6,215 I 6,515 I 6,720 I
C Maximum digging depth 5,720 6,220 6,770 7,220

D Maximum vertical wall 4,955 5,455 6,005 6,455

digging depth

E Maximum digging depth of 5,550 6,170 6,440 7,210

cut for 8 ’level

F Maximum digging reach 9,285 9,655 10,180 10,625

G Maximum digging reach at 9,090 9,470 10,000 10,460

ground

H Minimum swing radius 3,950 3,925 3,860 3,890

I I I I
Bucket digging force * I +I 6,700 kg I 14,500 kg I 14,500 kg I 14,500 kg 1

Arm crowd force * 14,700 kg 13,600 kg 11,900 kg 10,300 kg

’ -At power max ’ - Optional bucket cylinder is required

01-5
GENERAL GENERAL ASSEMBLY DRAWING

XOIAD025

Unit: mm
PC25OLC6 Arms

I 2.0 m I 2.5 m I 3.05 m I 3.5 m I

A Maximum digging height 9,300 9,340 9,660 9,780

B Maximum dumping height 6,505 6,350 6,750 7,125

Maximum digging depth 5,610 6,105 6,650 7,105

Maximum vertical wall 4,930 5,055 5,860 6,165

digging depth

Maximum digging depth of 5,380 5,895 6,475 6,950

cut for 8 ’level

F Maximum digging reach 9,285 9,655 10,180 10,625

G Maximum digging reach at 9,035 9,445 9,980 10,385

ground

H Minimum swing radius 3,950 3,925 3,860 3,890

Bucket digging force * +I 6,700 kg 14,500 kg 14,500 kg 14,500 kg

Arm crowd force * 14,700 kg 13,600 kg 11,900 kg 10,300 kg

’ -At power max ’ - Optional bucket cylinder is required

01-6
GENERAL SPECIFICATIONS

PC200-6, PC2OOLC-6
Machine Model PC200-6 PC2OOLC-6

Serial numbers A82001 and up A82001 and up

Bucket capacity (m3) 0.8 0.8

Operating weight (kg) 19,900 21,300

Maximum digging depth (mm) 6,620 6,620

Maximum vertical wall depth (mm) 5,980 5,980

Maximum digging reach (mm) 9,875 9,875

Maximum digging reach at ground level (mm) 9,700 9,700

Maximum digging height (mm) 9,305 9,305

Maximum dumping height (mm) 6,475 6,475

Maximum digging force (when using power max.) (Wkg)) 111.7 (11,400) 111.7 (11,400)
(124.5 (12,700)) (124.5 (12,700))

Swing speed (rpm) 11.5 11.5

Swing maximum slope angle (deg.) 20 20

Travel speed (km/h) Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5

Gradeability (deg.) 35 35

Ground pressure I (standard triple shoe width: mm) (MPa(kg/cm*)) 0.045 (0.46) I(600) 0.037 (0.38) I(700)

Overall length (for transport) (mm) 9,425 9,425

Overall width (mm) 2,800 2,800

Overall width of track (mm) 2,780 3,080

Overall height (for transport) (mm) 2,970 2,970

Overall height to top of cab (mm) 2,905 2,905

Ground clearance of counterweight (mm) 1,085 1,085

Minimum ground clearance (mm) 440 440

Tail swing radius (mm) 2,750 2,750

Minimum swing radius of work equipment (mm) 3,630 3,630

Height of work equipment at minimum swing radius (mm) 7,570 7,570

Length of track on ground (mm) 3,270 3,348

Track gauge (mm) 2,180 2,380

Height of machine cab (mm) 2,255 2,255

01-7
GENERAL SPECIFICATIONS

Machine model PC200-6 PC2OOLC-6

Serial numbers A82001 and up A82001 and up

Model S6D102-1

Type Ccycle, water-cooled, in-line, vertical, direct injection,

with turbocharger

No. of cylinders - bore x stroke (mm) 6-102x120

Piston displacement (cc) 5,880

Flywheel horsepower (kW(HP)/rpm) 108.1 (145) / 2,200

Maximum torque (Nm(kgmYrpm) 576.6 (58.8) / 1,600

High idle in H/O mode (rpm) 2130?60

Low idle in H/O mode (rpm) 1066?60

Minimum fuel consumption ratio (g/kWh(g/HPh) 210 (155)

Cranking motor 24 V, 5.5 kW

Alternator 24V,45A

Battery 12V, 150Ahx2

Type of radiator core cwx-4

Carrier roller

Track roller

Track shoe ~

Type, number Variable displacement piston type x 2,

0 gear type x 1
i
2 Delivery (Plmin) Piston type: 206 x 2
a4 gear type: 30
$2 Piston type: 34.79 (355)
Set pressure (MPa(kg/cm’))
gear type: 3.33 (34)

Type, number 6-spool type x 1

Control method Hydraulic type

Travel motor Piston type (with brake valve, parking brake) x 2

Swing motor Piston type (with safety valve, parking brake) x 1

Hydraulic cylinder Reciprocating piston

Hydraulic tank Box-shaped, open

Hydraulic filter Tank return side

Hydraulic cooler Air cooled (SF-3)

01-8
GENERAL SPECIFICATIONS

PC21 OLC-6
Machine Model PC21 OLC-6

Serial numbers A82001 and up

Bucket capacity (m’) 0.8

Operating weight (kg) 23,210

Maximum digging depth (mm) 6,620

Maximum vertical wall depth (mm) 5,355

Maximum digging reach (mm) 9,875

Maximum digging reach at ground level (mm) 9,700

Maximum digging height (mm) 9,180

Maximum dumping height (mm) 6,475

Maximum digging force (when using power max.) (Wkg)) 111.7 (11,400)
(124.5 (12,700))

Swing speed (rpm) 11.5

Swing maximum slope angle (deg.) 20

Travel speed (km/h) Lo: 3.0 Mi: 4.1 Hi: 5.5

Gradeability (deg.) 35

Ground pressure I (standard triple shoe width: mm) (MPa(kg/cm’)) 0.053 (0.54) I(600)

Overall length (for transport) (mm) 9,515

Overall width (mm) 2,800

Overall width of track (mm) 3,080

Overall height (for transport) (mm) 2,970

Overall height to top of cab (mm) 2,905

Ground clearance of countenveight (mm) 1,085

Minimum ground clearance (mm) 440

Tail swing radius (mm) 2,750

Minimum swing radius of work equipment (mm) 3,630

Height of work equipment at minimum swing radius (mm) 7,570

Length of track on ground (mm) 3,646

Track gauge (mm) 2,380

Height of machine cab (mm) 2,255

01-9
 Machine model PC21 OLC-6

A82001 and up

Jlodel S60102-1

fype Qcycle, water-cooled, in-line, vertical, direct injection,

with turbocharger

\lo. of cylinders - bore x stroke (mm) 6-102x120

‘iston displacement (cc) 5,880

Flywheel horsepower (kW(HP)lrpm) 108.1 (145) / 2,200

Maximum torque (Nm(kgmYrpm) 576.6 (58.8) I 1,600

High idle in H/O mode (rpm) 2130?60

Low idle in HI0 mode (rpm) 1066?60

Minimum fuel consumption ratio (g/kWh(glHPh) 210 (155)

Zranking motor 24 V, 5.5 kW

Uternator 24V,45A

3attery 12V, 150Ahx2

Type of radiator core cwx-4

Carrier roller 2 on each side

Track roller 9 on each side

Track shoe Assembly-type triple grouser

Type, number Variable displacement piston type x 2,

gear type x 1

Delivery (Plmin) Piston type: 206 x 2

gear type: 30

Set pressure (MPa(kg/cm’)) Piston type: 34.79 (355)

gear type: 3.33 (34)

Type, number 7-spool type x 1

Hydraulic type

Travel motor Piston type (with brake valve, parking brake) x 2

Swing motor Piston type (with safety valve, parking brake) x 1

iydraulic cylinder Reciprocating piston

-hydraulic tank Box-shaped, open

tiydraulic filter Tank return side

Hydraulic cooler Air cooled (SF-3)

01-10
GENERAL SPECIFICATIONS

PC220LC-6
Machine Model PC22OLC6

Serial numbers A82001 and up

Bucket capacity (m3) 1 .o

Operating weight (kg) 23,550

Maximum digging depth (mm) 6,920

Maximum vertical wall depth (mm) 6,010

Maximum digging reach (mm) 10,180

Maximum digging reach at ground level (mm) 10,000

Maximum digging height (mm) 9,380

Maximum dumping height (mm) 6,515

Maximum digging force (when using power max.) (Wkg)) 130.3 (13,300)
(142.1 (14,500))

Swing speed (rpm) 11.5

Swing maximum slope angle (deg.) 17.5

Travel speed (km/h) Lo: 3.0 Mi: 4.1 Hi: 5.5

Gradeability (deg.) 35

Ground oressure I (standard triple shoe width: mm) (MPa(kg/cm’)) 0.040 (0.41) / (700)

Overall length (for transport) (mm) 9,780

Overall width 0-W 3,280

Overall width of track (mm) 3,280

Overall height (for transport) G-4 3,160

Overall height to top of cab (mm) 2,905

Ground clearance of counterweight (mm) 1,085

Minimum ground clearance (mm) 440

Tail swing radius (mm) 2,860

Minimum swing radius of work equipment (mm) 3,860

Height of work equipment at minimum swing radius (mm) 7,760

Length of track on ground (mm) 3,830

Track gauge (mm) 2,580

Heiaht of machine cab (mm) 2,255

01-11
GENERAL SPECIFICATIONS

Machine model PC22OLC-6

Serial numbers A82001 and up

Model SAGDI 02-I

Type Ccycle, water-cooled, in-line, vertical, direct injection,

with turbocharger

No. of cylinders - bore x stroke (mm) 6-102x120

Piston displacement (cc) 5,880

Flywheel horsepower (kW(HP)/rpm) 129.8 (174) I 2,300

Maximum torque (Nm(kgm)/rpm) 624.7 (63.7) I 1,500

High idle in H/O mode (rpm) 2300 f 60

Low idle in H/O/ mode (rpm) 1066*60

Minimum fuel consumption ratio (g/kWh(g/HPh) 212 (156)

Cranking motor 24 V, 5.5 kW

Alternator 24V,45A

Battery 12V, 150Ahx2

Type of radiator core cwx-4

Carrier roller 2 on each side

Track roller 10 on each side

Track shoe Assembly-type triple grouser

Type, number Variable displacement piston type x 2,

gear type x 1

Delivery (Plmin) Piston type: 215 x 2

gear type: 31

Set pressure (MPa(kg/cm*)) Piston type: 34.79 (355)

gear type: 3.33 (34)

Type, number 6-spool type x 1

Hydraulic type

Travel motor Piston type (with brake valve, parking brake) x 2

Swing motor Piston type (with safety valve, parking brake) x 1

Hydraulic cylinder Reciprocating piston

Hydraulic tank Box-shaped, open

Hydraulic filter Tank return side

Hvdraulic cooler Air cooled (SF-3)

01-12
GENERAL SPECIFICATIONS

PC25OLC-6
Machine Model PC25OLC-6

Serial numbers A82001 and up

Bucket capacity (m3) 1.0

Operating weight (kg) 27,500

Maximum digging depth (mm) 6,650

Maximum vertical wall depth (mm) 6,580

Maximum digging reach (mm) 10,180

Maximum digging reach at ground level (mm) 9,980

Maximum digging height (mm) 9,660

Maximum dumping height (mm) 6,750

Maximum digging force (when using power max.) (Wkg)) 130.3 (13,300)
(142.1 (14,500))

Swing speed (rpm) 11.5

Swing maximum slope angle (deg.) 17.5

Travel speed (km/h) Lo: 2.2 Mi: 4.1 Hi: 5.1

Gradeability (deg.) 35

Ground pressure I (standard triple shoe width: mm) (MPa(kg/cm*)) 0.045 (0.46) I(700)

Overall length (for transport) (mm) 9,780

Overall width (mm) 3,290

Overall width of track (mm) 3,290

Overall height (for transport) (mm) 3,250

Overall height to top of cab (mm) 3,050

Ground clearance of counterweight (mm) 1,205

Minimum ground clearance (mm) 500

Tail swing radius (mm) 2,860

Minimum swing radius of work equipment (mm) 3,860

Height of work equipment at minimum swing radius (mm) 7,880

Length of track on ground (mm) 3,945

Track gauge (mm) 2,580

Height of machine cab (mm) 2,375

01-13
GENERAL SPECIFICATIONS

Machine model PC25OLC-6

Serial numbers f A82001 and up

Vlodel SAGDI 02-I

Type Ccycle, water-cooled, in-line, vertical, direct injection,

with turbocharger

Vo. of cylinders - bore x stroke (mm) 6-102x120

‘iston displacement (cc) 5,880

Flywheel horsepower (kW(HP)/rpm) 129.8 (174) I 2,300

Maximum torque (Nm(kgmYrpm) 624.7 (63.7) / 1,500

High idle in H/O/ mode (rpm) 2300 f 60

Low idle in H/O mode (rpm) 1066?60

Minimum fuel consumption ratio (glkWh(glHPh) 212 (156)

Cranking motor 24 V, 5.5 kW

Alternator 24V,45A

3attery 12V, 150Ahx2

Type of radiator core cwx-4

Carrier roller 2 on each side

Track roller 10 on each side

Track shoe Assembly-type triple grouser

Type, number Variable displacement piston type x 2,

gear type x 1

Delivery (Plmin) Piston type: 215 x 2

gear type: 31

Set pressure (MPa(kg/cm’)) Piston type: 34.79 (355)

gear type: 3.33 (34)

Type, number 6-spool type x 1

Hydraulic type

Travel motor Piston type (with brake valve, parking brake) x 2

Swing motor Piston type (with safety valve, parking brake) x 1

Hydraulic cylinder Reciprocating piston

Hydraulic tank Box-shaped, open

Hydraulic filter Tank return side

Hydraulic cooler Air cooled (SF-3)

01-14
GENERAL WEIGHT TABLE

PC200-6, PC2OOLC-6
Unit: kg
Machine model PC200-6 PC2OOLC-6

Serial number A82001 and up A82001 and up

Engine assembly 684 684

l Engine 480 480

l Damper 6 6

l Hydraulic pump 142 142

Radiator l oil cooler assembly 144 144

Hydraulic tank l filter assembly (excl. oil) 133 133

Fuel tank assembly (excl. fuel) 114 114

Revolving frame 1,637 1,637

Operator’s cab 287 287

Operator’s seat 29 29

Counterweight 3,280 3,280

Swing machinery 205 205

Control valve 230 230

Swing motor 9 9

Travel motor 123x2 123x2

Center swivel joint 42 42

Track frame assembly 4,666 5,308

l Track frame 2,374 2,864

0 Swing circle 276 276

l Idler 140x2 140x2

l Idler cushion 135x2 135x2

l Carrier roller 21 x4 21 x4

l Track roller 38x14 38x18

l Travel motor l final drive 425x2 425x2

Track shoe assembly

Standard triple grouser shoe (600 mm) 1,310x2 1,425 x 2

Standard triple grouser shoe (700 mm) 1,435x2 1,565 x 2

Wide triple grouser shoe (800 mm) 1,565 x 2 1,705x2

Wide triple grouser shoe (900 mm) 1,690 x 2 1.840x2

01-15
GENERAL WEIGHT TABLE

Unit: kg
Machine model PC200-6 PC2OOLC-6

Serial number A82001 and up A82001 and up

Boom assembly 1,334 1,334

Arm assembly 620 620

Bucket assembly 623 623

Boom cylinder assembly 187x2 187x2

Arm cylinder assembly 251 251

Bucket cylinder assembly 155 155

Link (large) assembly 78 78

Link (small) assembly 22x2 22x2

Boom pin 43+10x2+25+10+20 43+10x2+25+10+20

Arm pin 10x2 10x2

Bucket pin 20x2 20x2

Link pin 13x2 13x2

01-16
GENERAL WEIGHT TABLE

PC21 OLC-6
Unit: kc
Machine model PC21 OLC-6

Serial number I A82001 and up

Engine assembly I 685

l Engine 480

l Damper 6

l Hydraulic pump 142

Radiator l oil cooler assembly I 144

Hydraulic tank l filter assembly (excl. oil) I 133

Fuel tank assembly (excl. fuel) 114

Revolving frame 1,982

Operator’s cab I 290

Operator’s seat I 29

Counterweight I 4,730

Swing machinery I 205

Control valve I 230

Swing motor I 9

Travel motor I 123x2

Center swivel joint 42

Track frame assembly 5,318

l Track frame 2,870

0 Swing circle 280

l Idler 140x2

l Idler cushion 135x2

0 Carrier roller 21 x4

l Track roller 38x18

l Travel motor l final drive 425x2

Track shoe assembly

Standard triple grouser shoe (600 mm) 1,425 x 2

Standard triple grouser shoe (700 mm) 1,565 x 2

_
Wide triple grouser shoe (800 mm)
-
Wide triple grouser shoe (900 mm)

01-17
GENERAL WEIGHT TABLE

Machine model I PC21 OLC-6 I

Serial number A82001 and up

Boom assembly

Arm assembly

Bucket assembly 753

Boom cylinder assembly 187x2

Arm cylinder assembly 251

Bucket cylinder assembly 155

Link (large) assembly 78

Link (small) assembly 22x2

Boom pin 43+10x2+32+10+26

Arm pin 10x2

Bucket pin

Link pin 13x2

01-18
GENERAL WEIGHT TABLE

PC22OLC-6, PC250LC-6
Unit: kg
Machine model PC220LC-6 PC25OLC-6

Serial number A82001 and up A82001 and up

Engine assembly 699 699

l Engine 495 495

l Damper 6 6

l Hydraulic pump 142 142

Radiator l oil cooler assembly 163 163

Hydraulic tank l filter assembly (excl. oil) 133 133

Fuel tank assembly (excl. fuel) 114 114

Revolving frame 1,965 1,910

Operator’s cab 287 287

Operator’s seat 29 29

Counterweight 4,300 4,730

Swing machinery 205 205

Control valve 230 230

Swing motor 9 9

Travel motor 123x2 123x2

Center swivel joint 42 42

Track frame assembly 5,809 7,682

l Trackframe 3,286 4,312

0 Swing circle 280 716

l Idler 140x2 166x2

l Idler cushion 135x2 257x2

0 Carrier roller 21 x4 31 x4

l Track roller 38x20 52x16

l Travel motor l final drive 425x2 426x2

Track shoe assembly

Standard triple grouser shoe (600 mm) 1480x2 3,730 x 2

Standard triple grouser shoe (700 mm) 1,625 x 2 4,090 x 2

Wide triple grouser shoe (800 mm) 1,770 x 2 4,455 x 2

_ _
Wide triple grouser shoe (900 mm)

01-19
GENERAL WEIGHT TABLE

Unit: kg
Machine model PC22OLC-6 PC25OLC-6

Serial number A82001 and up A82001 and up

Boom assembly 1,627 1,627

Arm assemblv I 710 I 710

Bucket assembly 747 747

Boom cvlinder assemblv 215x2 215x2

Arm cylinder assembly 296 296

Bucket cylinder assembly 183 183

Link (large) assembly 80 80

Link (small) assembly 22x2 22x2

Boom pin 51 +10x2+31 +10+26 51 +10x2+31 +10+26

Arm pin 10x2 10x2

Bucket pin 20x2 20x2

Link pin 17x2 17x2

01-20
GENERAL FUEL, COOLANTS AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY @‘)

RESERVOIR KIND OF
FLUID -22 -4 14 32 50 68 86 104°F Specified Refill
-30 -20 -10 0 10 20 30 40°C

Engine oil pan 23.5 22.5

Damper case

Swing machinery case 6.8 6.8

6.3 5.5
Final drive case (each) PC25OLC-6 PC25OLC-6
Engine oil
8.0 7.4

Idler (each) 0.07 - 0.08 0.07 - 0.08

Track roller (each) 0.19 - 0.21 0.19 - 0.21

Carrier roller (each) 0.23 - 0.25 0.23 - .025

Pc200,Pc210
239

Hydraulic system PC22O,PC250 166

246

_
Fuel tank Diesel fuel 310

Pc200,Pc210
22.6 _
Cooling system Coolant See “Coolant” on page 01-23
PC22O,PC250
22.8

SPECIFIED CAPACITY: Total amount of oil including oil for components and oil in piping.
REFILL CAPACITY: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute

REMARK
0 When fuel sulphur content is less than OS%, change the engine oil at the normal periodic maintenance
interval described in the Operation and Maintenance Manual.
Change engine oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur content Change interval of oil in

engine oil pan

0.5 to 1 .O% % of regular interval

Above 1 .O% 1/4of regular interval

01-21
GENERAL FUEL, COOLANTS AND LUBRICANTS

OIL
0 When starting the engine in an atmospheric temperature of lower than 0°C (32°F) be sure to use an
engine oil grade of SAE 1 OW, SAE 1OW-30, or SAE 15W-40, even though the atmospheric temperature
goes up to 10°C (50°F) more or less in the day time.

0 We recommend genuine Komatsu oil which has been specifically formulated and approved for use in
engine and hydraulic work equipment application.

l Oil performance recommendations are as follows:

The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are
critical factors in maintaining engine performance and durability.
SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance classification
of CE or CF-4 is recommended.
NOTE: CD or CD/SF oils may be used with the interval given in the maintenance schedule in areas where
CE or CF-4 is not yet available.
A sulfated ash limit of 1 .O mass percent is suggested for optimum valve and piston deposit and oil con-
sumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85
mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher
ash oils can cause valve and/or piston damage and lead to excessive oil consumption.
The API service symbol displays the appropriate oil categories; the lower half may contain words to describe
oil energy conserving features. The center section identifies the SAE oil viscosity grade.

l Oil viscosity recommendations are as follows:

The use of multi-graded lubricating oil has been found to improve oil consumption control and improve
engine cranking in cold temperatures while maintaining lubrication a high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous
chart for oil viscosity recommendations for extreme climates.
NOTE: Single graded oils may be used if multi-graded oil is not available, but be sure to use oil that
matches the temperature in the table.
Special “break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same type
of oil during the “break-in” as specified for normal operation.

Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A.
Lubricating Oils Data Book For Heavy Duty Automotive and Industrial Engines.” The data book may be
ordered from the Engine Manufacturers Association, 401 North Michigan Avenue, Chicago, IL U.S.A. 60611.
The telephone number is (312) 644-6610.

ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there is no provisions
to keep the engine warm when it is not in operation, use a synthetic API performance oil classification CE or
CF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.

IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil
change intervals can decrease engine life due to factors such as; corrosion, deposits and wear.

01-22
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River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the
engine and radiator, and this will decrease heat exchange and cause overheating.
Water should meet the following guidelines.
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale
deposits. Water containing dissolved magnesium and calcium (the usual reason for water
hardness) above the specified amount will cause scale deposits to develop in the engine.

Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.

Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize
sludge deposits, scale deposits, corrosion or a combination of these.

If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To
determine if local water supplies meet these standards, water samples can be tested by water treatment
laboratories. “Softened” water that is prepared using common salt (sodium chloride) contains excessive
amounts of chlorides and should not be used.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is
shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 2000 hours. Therefore, it can be used as is even
in hot areas.

Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing proportions, see the Operation and Maintenance Manual.

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in
the coolant.

01-23
 10 STRUCTURE AND FUNCTION

Enginerelatedparts ....................................................................... IO -2
Radiator, oil cooler, aftercooler .............................................................. 10 -3
Powertrain ............................................................................... 10 -4
Finaldrive ................................................................................ 10 -5
Swingcircle .............................................................................. 10 -7
Swingmachinery .......................................................................... IO -8
Track frame, recoil spring ................................................................... IO -9
Trackshoe ............................................................................... IO -10
Hydraulic piping drawing .................................................................... IO -13
Hydraulic circuit diagram .................................................................... 10 -14
Hydraulictank ............................................................................ 10 -15
Hydraulicpump ........................................................................... IO -16
Controlvalve ............................................................................. IO -38
CLSS ................................................................................... 10 -47
Swingmotor .............................................................................. IO -92
Centerswiveljoint ......................................................................... 10 -95
Travelmotor ............................................................................. 10 -96
Valvecontrol ............................................................................. IO-107
Work Equipment, Swing PPC valve ........................................................... 1O-l 08
TravelPPCvalve .......................................................................... IO-112
ServicePPCvalve.. ....................................................................... IO-116
Safetylockvalve .......................................................................... IO-119
PPCaccumulator ......................................................................... IO-119
PPC shuttle, Travel junction valve ............................................................ 1 O-120
EPC,Solenoidvalve ....................................................................... IO-127
Hydrauliccylinder ......................................................................... IO-135
Additional filter for breaker .................................................................. 1O-l 36
Overloadwarningdevice .................................................................... IO-137
Hose burst protection valve (boom) ........................................................... 1O-141
Workequipment .......................................................................... IO-144
Electrical circuit diagram .................................................................... 1 O-l 45
Engine control system ...................................................................... 1O-l 49
Electronic control system ................................................................... 1O-l 54
Machine monitor system .................................................................... 1O-l 79

1O-l
STRUCTURE AND FUNCTION ENGINE RELATED PARTS

ENGINE RELATED PARTS

A-A 6 7 8

B-B c-c D-D E-E

X12AD046

1. Drive plate OUTLINE

2. Torsion spring l The damper assembly is a wet type.
3. Stopper pin Oil capacity: 0.75 P
4. Friction plate
5. Damper assembly
6. Air cleaner
7. Intake connector
8. Muffler
9. Rear engine mount
10. Front engine mount

1o-2